Wet sanding sponge; system and method for storing and using same

ABSTRACT

A wet sanding sponge comprises a portion of sponge or foam having sandpaper sewn thereto. Sponge or foam used in the invention may be natural or man-made. Applicant&#39;s wet sanding sponges may be selected to float in water or another lubricant by selecting a form or sponge of appropriate density. Man-made sponge preferably is an open-cell foam with a density lower than the density of water. The sandpaper should be sandpaper that may be used in water or lubricant without degrading, such as conventional water-resistant sandpaper. A method for storing and using the wet sanding sponge may include the use of a vessel containing lubricant along with one or more of the wet sanding sponges. The vessel may include a separator for reducing particulates in the lubricant.

This application is based on, and claims priority to: U.S. provisional application Ser. No. 60/767,163, filed Mar. 7, 2006, entitled Wet Sanding Sponge; 60/767,283, filed Mar. 15, 2006, entitled Wet Sanding Sponge; and 60/767,386, filed Mar. 23, 2006, entitled Wet Sanding Sponge and Method of Storage and Use.

FIELD OF THE INVENTION

The present invention relates to wet sanding sponges and systems and methods for storing and using wet sanding sponges.

BACKGROUND OF THE INVENTION

Wet sanding is commonly used to treat a surface for any of various purposes, including to smooth the surface, to remove flaws or adhered foreign matter from the surface, or to roughen the surface in preparation for a further treatment such as coating or painting. Wet sanding is commonly performed using a conventional wet sanding pad or sandpaper mounted to a sanding block, together with a spray bottle or hose for supplying water or another lubricant to the surface to be sanded. Lubricants used with wet sanding sponges are commonly water and water solutions. Water solutions of detergents or soap are particularly advantageous in reducing the tendency of particles to foul the sanding surface. These conventional wet sanding systems require the user to handle the conventional wet sanding pad or the sanding block and additionally to handle a sprayer or other lubricant source.

The conventional wet sanding pad is generally a portion of sandpaper adhered to a piece of rubber or closed-cell foam. Conventional wet sanding pads commonly suffer from an inconvenient tendency to curl up when placed in water or lubricant solution. In addition, when placed in a bucket or other vessel of lubricant solution, conventional wet sanding pads and sanding blocks generally sink to the bottom, where they come in contact with dirt and other particles.

SUMMARY OF THE INVENTION

Applicant has invented a wet sanding sponge comprising a portion of sponge or foam having sandpaper attached thereto. Sponge or foam used in the invention may be natural or man-made. If used in the invention, the man-made sponge preferably is an open-cell foam with a density lower than the density of water. The sandpaper should be sandpaper that may be used in water or lubricant without degrading, such as conventional wet sanding paper. A portion of sandpaper is sewn onto a portion of the foam or sponge.

Applicant has further invented a method for storing and using the wet sanding sponge according to the invention. The method may include the use of a vessel containing lubricant along with one or more of applicant's wet sanding sponges. Applicant's wet sanding sponges may be selected to float in water or another lubricant by selecting a form or sponge of appropriate density. Applicant's floating wet sanding sponges are well-suited for use with lubricant vessels because a floating wet sanding sponge does not sink to the bottom of the bucket where it may come in contact with dirt or other particles.

This general description is not intended to limit the scope of the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the bottom side of an example of a wet sanding sponge according to the invention.

FIG. 2 shows the top side of an example of a wet sanding sponge according to the invention.

FIG. 3 shows an example of a sheet of sandpaper for use in making a wet sanding sponge according to the invention.

FIGS. 4 shows an example of a base for use in making a wet sanding sponge according to the invention.

FIG. 5. shows an example of a example of a sheet of sandpaper and a base for use in making a wet sanding sponge according to the invention.

FIG. 6 shows an example of a vessel for use in a system according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

Applicant now describes in detail embodiments of the claimed invention. The described embodiments are examples. This detailed description is not intended to limit the scope of the invention as claimed.

In one embodiment of the claimed invention, as best seen in FIGS. 1 and 2, wet sanding sponge 10 has a generally flat shape with base 12 and bottom side 14. Base 12 has a generally flat shape; base 12 is made from a portion of sponge or foam. Wet sanding sponge 10 preferably is shaped and sized for easy handling in the user's hand; for example, dimensions of about 5½ by 4½ by ½ inches, or about 14.0 by 11.4 by 1.3 cm have been found to be convenient. Sponge or foam used in the wet sanding sponge may be natural or man-made. Suitable man-made foams include open-cell polyurethane foam, but any foam that is sufficiently durable, flexible, and preferably absorbent may be used. Preferably, sponge or foam used in the wet sanding sponge is selected so that the wet sanding sponge has a density lower than the density of water: this allows the wet sanding sponge to float when placed in a body of water or a water solution, even after the wet sanding sponge has absorbed some of the water or water solution. Alternatively, the density of the sponge or foam may be selected so that the wet sanding sponge floats in a desired lubricant other than water even after being wetted with some lubricant. The foam material of base 12 absorbs lubricant and thus is more convenient for wet sanding than materials that do not absorb lubricant.

Bottom side 14 has an abrasive surface of water-resistant sandpaper 16. The water resistant sandpaper may have any desired grain size and may optionally have a grain size from about 80 grit (coarse) to about 3000 grit (fine). The water-resistant sandpaper may be “wet and dry” silicon sandpaper as sold by Online Industrial Supply, or any equivalent sandpaper useable in water or lubricant.

Wet sanding sponge 10 has thread 18 sewn about its perimeter so as to secure water-resistant sandpaper 16 to base 12. As shown and preferably, thread 18 is stitched in such a fashion as to provide a barrier about the perimeter of water-resistant sandpaper 16 so as to reduce the likelihood that the user will inadvertently scratch a surface with water-resistant sandpaper 16. Thread 18 may advantageously be nylon, cotton, or other plastic or fibrous or other equivalent material or that is sufficiently soft to avoid scratching, abrading, or otherwise damaging the surface on which the wet sanding sponge is to be used and sufficiently strong to survive use of the wet sanding sponge.

By using sponge or open-cell foam instead of rubber or closed-cell foam, applicant's wet sanding sponge holds more water or lubricant than conventional wet sanding pads. Furthermore, when submerged in water or other lubricant, embodiments of applicant's wet sanding sponge may have less of a tendency to curl up than conventional sanding pads have.

In some embodiments of applicant's wet sanding sponge, the base 12 is not adhered to the sandpaper 16 by adhesive means but is instead sewn to the sandpaper 16. When these embodiments of the wet sanding sponge are used, a mechanical action is created between the sponge and sandpaper; this mechanical action is not found in conventional wet sanding pads in which the sandpaper is adhered to a piece of foam.

Applicant's wet sanding sponge may be used as part of a system comprising: a wet sanding sponge 10; a lubricant for use in sanding a surface with said wet sanding sponge; and a vessel, for example bucket 20, capable of containing a working amount of said lubricant. Preferably, the vessel may be equipped with a separator as shown in U.S. Pat. No. 6,161,701, issued to Biesingeron Dec. 19, 2000, which applicant hereby incorporates by reference. The separator is an apparatus for separating particulate dispersed in a liquid from the major volume of the liquid by entrapping most of the particulate in the bottom of a receptacle for holding the liquid. The separator comprises a substantially cylindrical member formed of a flexible material and having a top annulus and a bottom annulus, said cylindrical member adaptable for nesting in vertical disposition in a receptacle and conformable to the interior wall of the receptacle, said top annulus of said cylindrical member adaptable for being submerged below the surface of said liquid and having at least one opening; and a concave surface for substantially horizontal disposition depending from said cylindrical member and integrally formed therewith, said concave surface having at least one opening to allow for the passage of particulate therethrough.

Applicant's system may be used to perform sanding by a method comprising:

providing a system for sanding, comprising a wet sanding sponge; a lubricant for use in sanding a surface with said wet sanding sponge; and a vessel capable of containing a working amount of said lubricant.

placing said lubricant and said wet sanding sponge in said vessel; and then

removing said wet sanding sponge from said vessel; and then

sanding a surface with said wet sanding sponge; and then

placing said wet sanding sponge into said vessel containing said lubricant a second time. The three steps of removing said wet sanding sponge from said vessel; and then sanding a surface with said wet sanding sponge; and then placing said wet sanding sponge into said vessel containing said lubricant may be repeated as needed to complete the sanding task. Also, the user may advantageously employ more than one wet sanding sponge, so that at least one sponge remains in the vessel while the user is working with another wet sanding sponge.

The lubricant may preferably be water or a water solution. Water solutions of detergents or soap are particularly advantageous in reducing the tendency of particles to foul the sanding surface. The wet sanding sponge may preferably be coated or impregnated with detergent, soap, or other material so that the wet sanding sponge may form a lubricant solution by being placed in a vessel of water.

By storing the wet sanding sponge in a vessel with a lubricant such as water, the user may avoid the traditional use of and need for spray bottles, water hoses, or other required means to lubricate the sanding sponge before use. 

1. An article of manufacture comprising: a base, said base being a portion of base material selected from the following materials: natural sponge; man-made sponge; and open-cell foam; a water-resistant sandpaper secured to said base; and a piece of thread passing through said water-resistant sandpaper and through said pad in repeating fashion; wherein said article of manufacture has a density less than the density of water.
 2. A system for sanding, comprising: a wet sanding sponge, said wet sanding sponge being an article of manufacture according to claim 1; a lubricant for use in sanding a surface with said wet sanding sponge; and a vessel capable of containing at least an amount of said lubricant sufficient to permit said wet sanding sponge to float therein.
 3. A method for sanding, comprising: providing a system for sanding according to claim 2; placing said lubricant and said wet sanding sponge in said vessel; and then removing said wet sanding sponge from said vessel; and then sanding a surface with said wet sanding sponge; and then placing said wet sanding sponge into said vessel containing said lubricant a second time.
 4. A system for sanding according to claim 2, further comprising: a separator placed within said vessel, said separator being an apparatus for separating particulate dispersed in a liquid from the major volume of the liquid by entrapping most of the particulate in the bottom of a receptacle for holding the liquid, comprising: a substantially cylindrical member formed of a flexible material and having a top annulus and a bottom annulus, said cylindrical member adaptable for nesting in vertical disposition in a receptacle and conformable to the interior wall of the receptacle, said top annulus of said cylindrical member adaptable for being submerged below the surface of said liquid and having at least one opening; and a concave surface for substantially horizontal disposition depending from said cylindrical member and integrally formed therewith, said concave surface having at least one opening to allow for the passage of particulate therethrough.
 5. An article of manufacture according to claim 1, wherein said article of manufacture has a density less than the density of water.
 6. An article of manufacture according to claim 5, wherein said article of manufacture is able to float in water after being wetted with water.
 7. An article of manufacture according to claim 1, wherein said base material is polyurethane foam.
 8. An article of manufacture according to claim 1, wherein said article of manufacture comprises a lubricant concentrate, said lubricant concentrate being a material soluble in water.
 9. An article of manufacture according to claim 8, wherein said lubricant concentrate is comprising at least one of the following materials: detergent, soap, and surfactant.
 10. A system according to claim 2, wherein said wet sanding sponge has a density less than the density of water.
 11. A system according to claim 2, wherein said wet sanding sponge is able to float in water after being wetted with water.
 12. A system according to claim 2, wherein said base material of said wet sanding sponge is polyurethane foam.
 13. A system according to claim 4, wherein said base material of said wet sanding sponge is polyurethane foam.
 14. A system according to claim 4, wherein said base material of said wet sanding sponge is polyurethane foam.
 15. A system according to claim 2, wherein said lubricant is a water solution of a material comprising at least one of the following materials: detergent, soap, and surfactant.
 16. A system according to claim 2, wherein said article of manufacture comprises a lubricant concentrate, said lubricant concentrate being a material soluble in water.
 17. A system according to claim 16, wherein said article of manufacture comprises a lubricant concentrate, said lubricant concentrate comprising at least one of the following materials: detergent, soap, and surfactant.
 18. A method according to claim 3, wherein said base material of said wet sanding sponge of said system for sanding is polyurethane foam.
 19. A method according to claim 3, wherein said wet sanding sponge of said system for sanding has a density less than the density of water.
 20. A method according to claim 3, further comprising at least one additional repetition of the following steps: removing said wet sanding sponge from said vessel; and then sanding a surface with said wet sanding sponge; and then placing said wet sanding sponge into said vessel containing said lubricant. 